Catalytic alkylation



Patentecl May 3, 1949 UNITED STATES PATENT OFFICE Rope, Mullica Hill, N. 1.,

Vacuum Oil Company,

ration of New York assignors to Socony- Incorporated, a corpo- No Drawing. Application March 29. 1946, Serial No. 658,228

18 Claims.

This invention relates to the alkylation of saturated hydrocarbons, and is more particularly concerned with the catalytic alkylation of saturated hydrocarbons in the presence of novel alkylation catalysts.

It is well known in the art to react various types of saturated hydrocarbons with various substances, to efl'ect the union of molecules of the various types of saturated hydrocarbons with alkyl radicals produced by the various substances under the conditions of reaction. Processes embodying this reaction are called alkylation processes and the substances which supply the alkyl radicals are called alkylating agents. Accordingiy, in alkylation processes, a. charge comprising a mixture of an alkvlatable saturated hydrocarbon, called the alkyiatable saturated hydrocarbon reactant, and an alkylating agent is sub- Jected to high temperatures and pressures to produce a product called the alkylate. In general, since conditions of alkylation also cause side reactions involving primarily the alkylating agent. it is necessary to maintain a relatively low concentration of the alkylating agent in the charge. The only limit to the pressure used appears to be the feasibility of maintaining high pressures. on the other hand, the temperature used is limited b the degradation of the hydrocarbon reactants in the charge to low molecular weight hydrocarbons and the occurrence of side reactions, including, for example, polymerization of olelinic hydrocarbons, where they are utilized as alkylating agents, under high temperature conditions, which substantially the product obtained. The temperature of reaction, the time of reaction, the pressure employed and the control of the concentrationof the alkylating agent in the reaction zone alluded to are collectively referred to in the art as alkylating conditions.

The temperatures and to a certain extent, the pressures employed in alkylation operations depend upon whether the alkylation is eiiected in the absence or presence of alkylation catalysts. The two methods are generally referred to as thermal and catalytic alkylation, respectively. As is well known to those familiar with the art, thermal alkylation ordinarily involves the use of temperatures 01' about 750-1000 F. and pressures of the order of 4000 pounds per square inch or higher. Under these relatively severe conditions, the degradation of the hydrocarbon reactants in the charge, and the occurrence 01' side reactions involving the alkylating agents are somewhat marked. On the other hand, catalytic alkylation involves the use of appreciably less severe conditions, thereby assuring a high yield of desired alkylate by avoiding extensive degradation of the reactants and the marked occurrence of secondary reactions.

Several processes are known for carryin out catalytic alkylations. Apart from technological differences, these processes diiler from one another primarily in the type of alkylation catalyst employed. For example, sulfuric acid, hydrofiuoric acid, and various metal halides, especiaily aluminum chloride, have been used as alkylation catalysts. More recentLv. the use of complexes of boron triiluoride has also been proposed. For instance, it has been suggested to use complexes formed from boron trifluoride and phosphoric acid, from a boron halide and sulfuric acid, and from boron trifluoride and water.

Fluophosphoric acids are well known compounds. In accordance with a process disclosed in a. copending application, Serial Number 540,316, flied June 14, 1944, now United States Patent No. 2,409,248, fluophosphoric acids constitute excellent polymerization catalysts. However, as illustrated hereinafter, all our attempts to use monofluophosphoric acid, for example, as an alkylation catalyst have conclusively shown substantially no alkylation catalytic activity on the part of this acid, although confirming its marked tendency to promote polymerization reactions.

reduce the purity 01 We have now found that the product obtained by reacting a fluophosphoric acid, 1. e., monotluophosphoric acid or difluophosphoric acid, with boron trifluoride is an efllcient alkylation catalimit.

we have discovered new alkylation catalysts which promote alkylation reactions under relatively mild reaction conditions, thereby obviating the undesirable degradation of the hydrocarbon reactants in the charge and substantially completely avoiding the objectionable side reactions, both referred to hereinbefore.

It must be noted that although boron halides, such as boron triiiuoride, have been proposed as alkylation catalysts, under the relatively mild reaction conditions used herein, and as illustrated hereinafter, boron trifluoride, for example, does not promote alkylation reactions.

Accordingly, it is an object 01' the present invention to provide an eflicient process for alkylating alkylatable hydrocarbons. Another object is to provide an emcient catalytic process for alkylating alkylatable hydrocarbons. A more specific object is to provide new alkylation cata- -in the presence of the iysts. A very important oblect is to aflord a process ior alkylating alkylatable hydrocarbons product obtained by reacting a fluophosphoric acid with boron trifluoride. Other objects and advantages or the present invention will become apparent to those skilled in the art from the foliowins descriphydrocarbon with an alkylatlng agent in the presence oi the product obtained by reacting a duophosphoric acid with boron trifluoride. under alkylating conditions.

The alkylatable saturated hydrocarbons utilized in the process the present invention comprise iso. alkyl alicyclic and aromatic hydrocarbons.

In general, any isoparai'ilnic hydrocarbon may be used in our process. In the production of valuable constituents of motor fuels. isobutane is the iso hydrocarbon most commonly subiected to alkylation with monooleiinic hydrocarbons to produce more highly-branched paraiiinic hydrocarbons. The higher branched-chain paraflinic hydrocarbons, such as isopentane, being themselves desirable constituents of motor fuels, are less often subjected to alkylation. Nevertheless, in accordance with the process of our invention, these branched-chain paraihnlc hydrocarbons may be alkylated. if desired.

Non-limiting examples of the alkylatable alkyl alicycllc hydrocarbons which may be utilized in our process are methyl cyclopentane and dimethyl cyclohexane.

Benzene, toluene, nieces. and other polyalkyl benzenes, naphthalene. alkyl and polyalkyl naphthalenes, and other polynuclear aromatic hydrocarbons which can be alkylated ordinarily may be used as the alkylatable hydrocarbon reactant in the process of our invention. These aromatic hydrocarbons may be subjected to treatment in accordance with our process to produce more highly-branched aromatic hydrocarbons as well as monoalkyl and polyalkyi aromatic hydrocarbons.

In general, any olennic hydrocarbon can be used as an alkylating agent in the process 0! our invention. These oleflnic hydrocarbons may be monooleflnic hydrocarbons; cyclic oleflnic hydrocarbons, such as cyclohexene; or dioleiinic hydrocarbons, such as butadlene. The monoolennic hydrocarbons used may be either normally gaseous or normally liquid, and include ethene, pronene, butenes, pentenes, and higher normally liquid oleiinic hydrocarbons. such as octenes or decenes. Alkynes. such as methyl acetylene, and terpenes may be utilised also as misting agents, it desired.

In view of the state of the art, it must be clearly understood that a monooleflnic hydrocarbon may be produced in situ under the conditions of operation from a wide variety or compounds. Such olefin-producing compounds have been used extensively as alkylating agents in alkylation open ations, and comprise. for example, alcohols. esters, ethers, and alkyl halides. Accordingly, any alcohol, ester. ether or alkyl halide or compound which is capable of producing the corresponding monooleilnc hydrocarbon by dehydration or splitting under the conditions of our process must be considered to be included herein as a suitable alkylating agent. Obviously. for reasons of economy, particularly when operating on a commercial scale, we preiei to iise mohooieiinic hydrocarbons as the aikylating agents.

The alkylatable saturated hydrocarbon reactants and the alkylating agents to be used in the process of the present invention may be obtained or derived irom any suitable source, as is well known in the art. and may be used either in the pure state or in admixture with other constituents not undesirable. For example, in the preparation of valuable constituents or motor fuels, a conventional and preferred source oi paramnic and oieiinic hydrocarbons suitable as feed stocks for the process of the present invention, is the mixture of butenes and butanes obtained from either thermal or-catalytic cracking operations; in the preparation or useful solvents, of valuable constituents of motor fuels or 01 intermediates '-utllizab1e in organic syntheses, aromatic hydrocarbons may be obtained irom petroleum, by the catalytic or thermal cracking of higher aromatic hydrocarbons, by the distillation or coal, by the dehydrogenation of suitable alicyclic hydrocarbons, by the dehydrogenation and cyclization of aliphatic hydrocarbons. etc, all as is well known to those familiar with the art.

There appears to be nothing critical in the proportions of reactants used in the charge. However, it is desirable. as in known alkylation processes, to keep the concentration of the alkylating agent relatively low during the alkylation reaction. in order to avoid the side reactions involving the alkylating agent as much as possible. Accordingly, it is advisable, for example, to maintain the monooieflnic hydrocarbon concentration in the charge below 50%, and preferably, below 25% by volume. In continuous operation, this is eflected by introducing the alkylating agent at a number of points in the reaction zone or by adding the alhlating agent to a recirculating excess of alkylatable hydrocarbon reactant.

The novel catalyst which we use is the product obtained by reacting boron triilucride with a fluophosphoric acid. For the purpose of the present invention, we contemplate using either monoilum phosphoric acid (W) or difluophosphorlc acid (HPOaFa). although we prefer to use the monoflucphosphoric acid. This is ordinarily achieved by saturating the acid with the boron trifluoride. Without any intent of limiting the scope of the present invention, we believe that our catalyst is a compound formed by the reaction between one molecule of monofluophosphorle acid or diiiuophosphoric acid and one molecule of boron trifluoride. Our belief is based in part on the following which illustrates a method oi preparing our catalyst:

50 grams (0.50 mole) of monofluophosphoric acid were placed in a stainless steel autoclave of 900 ml. capacity which was fitted with a stirrer and immersed in a water bath. The acid was kept at a temperature of 20 C. and was saturated with boron triiiuoride by maintaining the monofluophosphoric acid in an atmosphere of boron trifluoride gas until no further boron trlfluoride was absorbed, as indicated by a steady reading on a pressure gage attached to the autoclave. 88 grams of the catalyst were obtained indicating that 38 grams of boron trifluoride (0.56 mole) had entered the product. This represents approximately a 1:1 compound. A little more boron trifluoride than that corresponding to a 1:1 ratio entered the product.

Other-boron halides may be used in the preparation oi our catalyst. For example, boron trichloride may be used instead or boron trifluoride.

The amount of catalyst to be used may vary within wide limits, and, of course, depends upon the amounts of the reactants employed. Ordina'rily, in batch operations, we use the catalyst in amounts varying between about 8% and about 20%, based on the weight of the charge, and in continuous operation, ordinarily not less than 100 parts of the charge is reacted in the presence of one part of catalyst.

In carrying out our process, we ordinarily use temperatures varying between about -l C. and about 80 0., preferably, temperatures varying between about 0 C. and about 50 C. It will be seen that an important feature of the process of the present invention is the relatively low reaction temperature employed. As a result, degradation of the hydrocarbon reactants in the charge to low molecular weight hydrocarbons and the pronounced occurrence of side reactions are substantially completely avoided. Consequently, in our process, we obtain high yields of a high-grade product which is almost entirely saturated in nature and is substantially free from impurities.

Pressure is not an important factor. Accordingly, atmospheric, subatmospheric or superatmospheric pressure may be employed. Consequently, the reaction embodied in the process of the present invention may be effected in the liquid phase, vapor phase or mixed phase. We prefer to operate in the liquid phase when using butenes as the alkylating agents, and hence, use enough pressure on the reactor to keep the butenes liquid.

The process may be carried out as a batch, continuous or semicontinuous type of operation. Particularly when the process is carried out on a commercial scale, economic considerations make it preferable to operate in a continuous manner. For eflicient operation, whether the process is carried out on a batch or continuous basis, it is essential that the hydrocarbon reactants be intimately contacted with the catalyst of our invention for the length of time necessary to achieve the alkylation, ordinarily, from 0.1 to 20 minutes. This may be effected in several ways and in apparatus which are well known in the art.

The following detailed examples are for the purpose of illustrating the process of our invention and the advantages thereof, it being clearly understood that the invention is not to be considered as limited to the specific reactants or to the manipulations and conditions set forth therein. As it will be apparent to those skilled in the art, a wide variety of other reactants may be used.

Example 1 Fifty grams of monofluophosphoric acid saturated with boron trifluoride were placed in a stainless steel autoclave of 900 ml. capacity, which was fitted with a stirrer and immersed in a water bath kept at a temperature of 20 0. Subsequently, 300 c. c. of isobutane were pumped into the autoclave and then 300 c. o. of isobutene were added at a rate oi c. c. per minute. After the addition of the isobutene, stirring was continued for 60 minutes. The catalyst was then withdrawn. and the product was stabilized by subjecting the same to a distillation in a glass fractionating column until the vapor temperature had reached 25 C. 140 grams of stabilized product were obtained. This product was washed twice with water, once with a dilute aqueous solution of sodium hydroxide, and again, once with water. 122 grams of washed product were obtained. The washed product was subjected to a distillation to produce three fractions and a residuum. The first fraction The run set forth with the exception that 400 c. c. of isobutane were reacted with 200 c. c. of isobutene. The washed product weighed 106 grams. This product was subjected to distillation with the following results:

Per Cent by B 1 Fraction Weight of mm m Product Number 25-170 C 71. 5 0.0 I'm-185 0.. l4.4 Mfr-230 C 3. 7 Residue l0. 4 43. 8

Example 3 The run set forth in Example 1 was repeated with the exception that 400 c. c. of isobutane were reacted with 200 c. c. of propylene. The washed product weighed '74 grams. This product was subiected to distillation with the following results:

' and placed in a 6-liter to distillation with Per Cent by B 1 Fraction Weight of tom us Product Number 60. 4 0.0 170-185 O. 5. 3 -210 C. 2.5 Residue 31.8

Example 4 In order to prepare alkylate in amounts suflicient for a motor test, 200 grams oi monofiuophosphoric acid were saturated with boron trifluoride autoclave equipped with a stirrer and surrounded with a water jacket kept at a temperature of 20 C. 3000 c.'c. of isobutane were pumped into the autoclave and 1500 o. c. of isobutene were added at a rate of 80 c. e. per minute. After the addition of the isobutene, stirring was continued for 60 minutes. The catalyst was then withdrawn and the product was stabilized and washed as in Example 1. The washed prodnot which weighed 1159 grams was then subjected the following results:

The first two fractions were combined and a quart sample was leaded with 4.0 mL/gal. of lead tetraethyl and tested in accordance with the A. S. T. M. knock test for aviation fuels (D614- 44T) and found to have a rating of iso +0.45, a representative figure for alkylate.

Example 5 The run set forth in Example 1 was repeated with the exception that 400 o. c. of isobutane were reacted with 200 c. c. of isobutene, and 50 in Example 1 was repeated accuse grams oi monoduopbesphoric acid were used instead of the monofluophosphoric acid saturated with boron triiiuoride. The washed product weighed grams. This product was subjected to distillation with the following results:

Per Cent by Fraction w to! egg uct 10 a 110.8 H10. an 00.1 at no no The low yield oi. product boiling in the muse the high bromine numbers or the lractions boiling in the ranaes -170" C. and

than monoiiuophospolymerization catalyst rather than as an allwlation catalyst.

Example 6 The run set forth in Example lwas repeated with the exception that 400 c. c. of isobutane were reacted with 200 c. c. of lsobutene and that the isobutane was saturated with boron trlfluoride prior to the addition of the isobutene. No monofluophosphoric acid saturated with boron trlfluoride was employed. The washed product The low yield of product boiling in the range 25-170 C. and the high bromine numbers of the Iractions boiling in the ranges 25-170 C. and 170-185" C. show that boron trifluoride alone is a polymerization catalyst and not an alkylation catalyst.

For the purpose of facilitating comparison of the results obtained in comparable runs, the former are set forth in the followina table:

those skilled in the art will readil Such variations and modifications to be within the purview and scope or the appended claims.

We claim:

1. In the process for alkylating alkyiatable hydrocarbons, which includes contactinl an al. hlatable hydrocarbon with an alkylating agent. under alkylatinz conditions; the improvement which comprises contactina said alkylatable hydrocarbon with an alkylatin: went. in the presence of the product obtained by reactln: a fluophosphoric acid selected from the group ing or monofluophosphorlc acid and difluophoh phoric acid, with boron triiluoride. as the catalyst.

2. The process tor alkylatinz alhlatable h!- drocarbons, which comprises contactina an alaikylatins scent. in the presence oi the product obtained by reacting monotluophosphoric acid with boron trifluoride as the catalyst, under alkylatins conditions including temperatures vanilla between about minus 10 C. and about 80 C.

3. The process for carbons, which comprises contacting an alkylatable hydrocarbon with an alkyiatins agent. in the presence or monofluophosphorlc acid saturated with boron trifluoride as the catalyst, 1mder alkylating conditions includinl tempera {gates varying between about 0 C. and about 4. The process tor alkylating alkylatable isoparafllnic hydrocarbons, which comprises contacting an alkylatable iso hydrocarbon with a monooleflnic hydrocarbon.-in the presence or the product obtained by reacting a fluopholphorlc acid selected from the group consisting of monofluophosphoric acid and difluophosphoric acid, with boron trifluoride. as the catalyst, under allrylating conditions.

5. In the process for alkylating alkylatable isoparaflinic hydrocarbons, which includes contacting an allwlatabie isoparamnic hydrocarbon with a monooleilnic hydrocarbon, under alkylating Per Cent by Weight of Product in Each Bromine Numberofltadi Fraction Fraction Example No.

x u m w 20-110 0. m-m' o. lat-I10 o. Residue I n m w ram-Porter. 11.0 14.4 3.1 10.4 0.0 43.3 H.rro..-.-. 10.: no as aao 110.0 00.7 14.0 as, 11.1 eai 0.0 are 142.1 102.1 am It is quite evident from these data that monoconditions; the improvement which comprises fluophosphoric acid when used alone and boron trifluoride' when used alone possess negligible tendencies to promote alkylatlon reactions. However, it is quite apparent from these data that the complex obtained from monofluophosphoric acid and boron trilluoride is an eiilcient and highly desirable alkylation catalyst.

It will be apparent that the present invention provides an eflicient process (or alkylatins saturated hydrocarbons. Our process is of considerable value in making available alkyl saturated hydrocarbons which are useful. for example, as intermediates in organic synthesis, as solvents, and as constituents of motor fuels.

Although the present invention scribed in conjunction with has. been depreterred embodicontacting said alkylatable isoparaillnlc hydrocarbon with a monooleflnic hydrocarbon, in the presence or the product obtained by reacting monoiluophosphoric acid with boron triliuoride as the catalyst. at temperatures varying between about minus 10 C. and about 30 C.

6. The process lor alkylatlng alkylntable isoparamnic hydrocarbons, which comprises contacting an alkylatable isoparafllnic hydrocarbon with a monooleflnic hydrocarbon, in the presence oi monofluophosphoric acid saturated with boron trifluoride as the catalyst, under alkyiatina con ditions including temperatures varyina between about 0" C. and about 50 C. v

l. The process for alkylating isobutane. which comprises contactina isobutane with a butane, in

s,seo,sss

the presence of monofluophoephoric acid saturated with boron trifluoride as the catalyst. under alkyiating conditions, including temperatures varrlns between about 0' O. and about 50 C.

I. The process for aikylating alkylatable aromatie hydrocarbons, which comprises contacting an aikylstabie aromatic hydrocarbon with .a monooieiinic hydrocarbon. in the presence of the product obtained by reacting a iiuophoaphoric acid selected from the troop consisting of monofluophospho'ric acid and difluophow oric acid, with boron trifluoride. as the catalyst, under alvlating conditions.

The process tor matic hydrocarbons,-- which comprises contacting an alkyiatable aromatic hydrocarbon with a monooiednic hydrocarbon. in the presence of the product obtained by--reacting monoiiuophosphoric acid with boron trifluoride as the catalyst. under aihylating conditions includins temperatures between about minus 10' C. and about 10. In the process for alkyiatins alkrlatabie aromatic hydrocarbons, which includes contactin: an alkylatable aromatic hydrocarbon with a monooletinic hydrocarbon, under aikylating conditions: the improvement which comprises contaeting said alkyla'table aromatic hydrocarbon with a monooleflnic hydrocarbon, in the presence of monoiiuophosphoric acid saturated with boron triiiuoride as the catalyst, at temperatures vary hlblltlnh alkylatabie N'O- tacting ssidaikyiatable alicyclic hydrocarbon with a monooieiinic hydrocarbon. in the presence oi the product obtained by reacting a fluophosphoric acid selected from the group consisting oi monoiiuophosphoric acid and difluophosphoric acid, with boron trifluoride, as the catalyst.

12. The process for alkylating alkyiatable alieyclic hydrocarbons, which comprises contacting an aikylatable alicyclic hydrocarbon with a The following references are of record in the tile of this patent: V

UNITED STATE PATINTB Number Name Date 1,671,517 Edeleanu May 29, 1928 2,317,694 Ott Apr. 37. 1943 3,363,333 Beyerstedt Nov. iii, 1944 6,731 Ipatiei! et at. Jan. O. 1045 2,401,884 Schuiee et a1. June 11, 1946 

